Mounting arrangement for a knot brush

ABSTRACT

A knot brush with a knot plate having a plurality of perforations disposed circumferentially about the plate near an outer rim. A plurality of mounting holes are formed through the knot plate and are spaced apart from one another. Each mounting hole is located at a radial position that is inward from the perforations. A plurality of wire bundles are attached to the knot plate. Each wire bundle includes a center portion extending through a perforation and two end portions twisted together securing the bundle to the knot plate. Two side plates are attached to the knot plate. Each side plate includes protrusions extending out from the side plate and into the mounting holes. One side plate is punched into a protrusion on the other side plate forming an interlocking button that extends from the surface of the side plate and locking the side plates together.

FIELD OF THE INVENTION

The present invention is directed to knot brushes and, moreparticularly, to an improved mounting arrangement for a knot brush thatsimplifies assembly while providing support for the knot.

BACKGROUND

Knot brushes have been around for many years. U.S. Pat. No. 4,504,997describes one conventional knot brush design. The brush includes aplurality of radially extending twisted wire bundles. Each wire bundleis separately attached to a central disc or knot plate. The attachmentis provided by passing a wire bundle through one of a plurality ofcircumferentially spaced holes formed in the knot plate and thentwisting both ends of the wire bundle together to form the twisted knot.

In order to support the wire bundle, conventional knot brushes includeside plates that are attached to opposite sides of the knot plate andcrimped around the wire bundles to secure the knots. The side plates andknot plate are then welded together to form the final brush assembly.These conventional brushes are costly and time consuming to manufacture.

A need exists for an improved knot brush mounting arrangement thatsimplifies assembly while providing support for the knot.

SUMMARY OF THE INVENTION

The present invention is directed to an improved knot brush assemblythat includes a knot plate having a plurality of perforations formedthrough the knot plate and disposed circumferentially about the platenear a radially outer rim. A plurality of mounting holes are formedthrough the knot plate and are spaced apart from one another, Eachmounting hole is located at a radial position that is inward from theperforations.

A plurality of wire bundles are attached to the knot plate. Each wirebundle includes two opposed end portions with the center of the wirebundle extending through an associated perforation in the knot plate.The end portions are at least partially twisted together so as to securethe bundle to the knot plate.

The knot brush includes two side plates that are attached to the knotplate. Each side plate includes an annular central portion and curvedsupport rim. The curved support rim is configured to assist insupporting the wire bundles. Each side plate also includes at least twoprotrusions extending outward from the surface of the annular portionand forming a recess on the opposite side of the plate. The protrusionsare spaced apart from one another on the side plate and located at aradial position relative to the center of the side plate such that eachprotrusion seats within an associated mounting hole. In order to attachthe side plates to one another, a portion of one side plate is deformedinto the protrusion of the other side plate, thereby mechanicallylocking the two plates together. Preferably the deformation is formed bypunching the material of one plate into the other so as to form a raisedbutton in the recessed portion of the other plate. The attachment of thetwo side plates together retains knot plate between the two side plates.

In one embodiment, the perforations are slotted holes formed in the knotplate and are spaced substantially equally apart from one another and ata common radial position from the center of the knot plate. Each sideplate includes half as many protrusions as there are mounting holes inthe knot plate.

Preferably there are six mounting holes substantially equally spacedcircumferentially on the knot plate and three protrusions on each sideplate substantially equally spaced circumferentially on the centralportion of the side plate. The side plates are preferably substantiallyidentical except that the protrusions on one side plate are offset fromthe protrusions on the other side plate by 60 degrees when the sideplates are mounted to the knot plate.

A method of assembling the knot brush is also disclosed.

The foregoing and other features of the invention and advantages of thepresent invention will become more apparent in light of the followingdetailed description of the preferred embodiments, as illustrated in theaccompanying figures. As will be realized, the invention is capable ofmodifications in various respects, all without departing from theinvention. Accordingly, the drawings and the description are to beregarded as illustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, the drawings show a formof the invention which is presently preferred; it being understood,however, that the invention is not limited to the precise arrangementand instrumentality shown.

FIG. 1 is a plan view of a completely assembled knot brush according tothe present invention.

FIG. 2 is a plan view of a knot plate used in the knot brush of FIG. 1illustrating one bristle bundle knotted to the knot plate.

FIG. 2A is an enlarged view taken from FIG. 2 illustrating theperforations.

FIG. 3 is a cross-sectional side view of the knot brush.

FIG. 4 is an exploded cross-sectional side view of the know brush priorto assembly.

FIGS. 5A-5C illustrate the process of mechanically interlocking the twoside plates together.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings, wherein like numerals indicate like elements,an embodiment of the knot brush 10 is shown that is preferred. The knotbrush 10 includes a knot plate 12 which has a plurality ofcircumferentially spaced perforations or holes 14 in close proximity toa rim 16 of the plate 12. Preferably the perforations are evenly spacedand located at a common radial position.

In the illustrated embodiment, the knot plate has a diameter of about4.38 inches and a thickness of about 0.110 inches. The perforations 14are preferably slotted or elliptical holes. Each hole has a length (H1)of about 0.200 inches and a width (H2) of about 0.125 inches. There arepreferably about 76 holes spaced substantially equally apart andcentered at a radial distance (H3) about 1.984 inches from the center ofthe knot plate.

Wire or bristle bundles 18 are attached to the plate in a conventionalmanner by passing an end portion of the bundle 18 through one of theperforations 14 and looping it back. The end portions are then twistedtogether at least partially along the length of the bundle, so as toform a twisted bundle or knot that is looped about through theperforation. The are other ways known to those skilled in the art forattaching wire bundles to the knot plate and, thus, no furtherdiscussion is necessary.

The knot brush 10 includes two side plates 20, 22, that are located oneither side of the knot plate 12 and attached to the knot plate 12 asdiscussed below. The side plates 20, 22 are preferably identical withrespect to their general configuration and each include an annularcentral portion 24 that is substantially planar in shape, and a curvedsupport rim 26 with a radius that is designed to substantially match theradius of the looped portion 28 of the wire bundle. This curved supportrim 26 assists in holding the wire bundles 18 in place.

In the illustrated embodiment, each side plate 20, 22 preferably has adiameter of about 4.72 inches and a thickness of about 0.05 inches.

In conventional knot brushes, the side plates and knot plate are weldedtogether. However, doing so adds additional time and expense to themanufacturing process. The present invention overcomes the deficienciesassociated with the prior art mounting arrangements. More particularly,the knot plate 12 includes a plurality of mounting holes 32 formedthrough the plate, radially inward from the perforations 14. As shownthe figures, the holes are spaced apart from each other. In onepreferred embodiment, there are an equal number of holes. The mountingholes 32 are preferably equally spaced circumferentially and at a commonradial location.

In the illustrated embodiment, the mounting holes 32 are formed throughthe knot plate 12 with their centers located on a 2.992 inch diameterbase circle, i.e., a radius (M1) of 1.496 inches from the center of theknot plate 12. Each mounting hole 32 preferably has a diameter (M2) ofabout 0.610 inches and is angularly spaced (M3) 60 degrees from anadjacent hole 32.

Each side plate includes at least two and more preferably at least threeprotrusions 34 extending outward from one surface of each side plate andare designed to seat within the mounting holes 32 as will be discussedbelow. Each protrusion 34 forms a recess 36 on the opposite surface ofthe side plate. In one preferred embodiment, each side plate includeshalf as many protrusions as there are mounting holes in the knot plate.In the illustrated embodiment, there are three protrusions 34substantially equally spaced circumferentially on the planar portion ofthe side plate at a radial distance (P1) of about 1.496 inches from thecenter of the knot plate 12. Thus, the protrusions are preferablylocated at the same radial location on the side plates as the mountingholes are on the knot plate.

The protrusions 34 preferably have a size and shape designed to matewith the mounting holes 32. More specifically, the protrusions 34 aredesigned to seat within the mounting holes as shown in FIG. 3. In theillustrated embodiment, the protrusions are substantially circular inshape with an outer diameter (P2) of about 0.571 inches and a depth (P3)of about 0.105 inches. The protrusions 34 extend (protrude) out from thesurface of the side plate that contacts the knot plate. The protrusionsare spaced (P4) approximately 120 degrees apart from one another in theillustrated embodiment.

As should be apparent from the above discussion, in the preferredembodiment, since each side plate includes half the number ofprotrusions as there are mounting holes in the knot plate, and since theprotrusions are equally spaced, identical side plates can be used onopposite sides of the knot plate; provided that one plate is rotated soas to orient its protrusions 34 so that they do not align with theprotrusions on the other side plate. For example, as shown in theillustrated embodiment, since each side plate includes threeprotrusions, rotating one side plate 60 degrees will result in eachprotrusion on a side plate seating within a unique mounting hole. Thisreduces the number of component parts that are necessary to form theknot brush assembly 10.

In order to secure the sides and knot plates to each other, the presentinvention uses a mechanical interlocking mechanism. One of the problemswith trying to interlock conventional knot brushes is that it is notpossible to physically deform two side plates and a knot plate. Thepresent invention overcomes this problem by forming the interlocking orself riveting in the holes of the knot plate. Specifically, a portion ofone side plate is deformed into the protrusion on the other side platecausing the material of the two side plates to interlock, therebypreventing disengagement. The deformation of one side plate into theprotrusion creates a raised button or rivet shaped swelling 38 orprotuberance on the opposite side of one of the layers that ispreferably located within the recess 36. The button 38 interlocks thetwo layers together. Since the side plates are interlocked to oneanother within the holes of the knot plate, the knot plate is securedbetween the side plates as shown in FIG. 3. Also, locating the button 38in the recess 36 minimizes sharp protrusions on the knot brush/

The knot brush 10 is preferably formed as follows. The perforations 14and mounting holes 32 are formed in the knot plate 12 using anyconventional method known to those skilled in the art including lasercutting, punching, drilling, casting, etc. The side plates 20, 22,including the protrusions, are likewise formed using any conventionalmethod known to those skilled in the art.

A side plate is placed on either side of a knot plate and oriented suchthat each protrusion 34 aligns with an associated mounting hole 32. Oneof the benefits of the present invention is the mounting holes in theknot plate provide an easy mechanism for aligning the side plates sincethe protrusions will naturally seat within the holes.

In order to attach the side plates together a self-riveting process isused. This process involves punching one side plate into the protrusionon the other side plate so as to form a button or rivet shaped swellingor protuberance on the opposite side of one of the layers. Theprotuberance interlocks the two layers together. One system that theapplicants have found to work is the TOX® cinching system available fromTOX Presstechnik LLC, Warrenville Ill. That system is generally depictedin FIGS. 5A-5C and uses a punch 50 and die 52. The punch 50 is forcedinto the outer facing surface of one side plate and deforms the aportion of the first side plate into the protrusions of the second sideplate as shown in FIG. 5B and into the die 52. The die forces thedeformed material to create the button. The punch 50 and die 52 arewithdraw leaving a button 38 of interlocked material as shown in FIG.5C. Pressure can be applied using an hydraulic, pneumatic or similarpress. This process effectively self rivets the side plates to eachother.

The use of the novel self-riveting process eliminates the need for aseparate and costly welding operation. The size of the buttons discussedabove result in more metal of the side plates engaging the knot platethan conventional welding, thus forming a better and stronger attachmentto the knot plate.

While the illustrated embodiment shows the side plates with theprotrusions formed prior to assembly, it is also contemplated that theprotrusions can be formed during the step of pressing the side platesinto the knot plate. The die can force the material of the side plate todeform into the mounting holes during the attachment process as thebutton is formed.

Although the invention has been described and illustrated with respectto the exemplary embodiments thereof, it should be understood by thoseskilled in the art that the foregoing and various other changes,omissions and additions may be made therein and thereto, without partingfrom the spirit and scope of the present invention.

1. A knot brush comprising: a knot plate having a plurality ofperforations formed through the knot plate, the perforations beingdisposed circumferentially about the plate near a radially outer rim ofthe knot plate, and a plurality of mounting holes formed through theknot plate, the mounting holes being spaced apart from one another onthe knot plate, each mounting hole located at a radial position inwardfrom the perforations; a plurality of wire bundles attached to the knotplate, each wire bundle including two opposed end portions with a centerportion extending through an associated perforation in the knot plate,the end portions being at least partially twisted together so as tosecure the bundle to the knot plate; first and second side platesattached to the knot plate, each side plate including an annular centralportion and curved support rim, the curved support rim adapted to assistin supporting the wire bundles, each side plate including at least twoprotrusions extending out from the surface of the annular portion, theprotrusions being spaced apart from one another and forming a recess onthe opposite surface of the side plate, each protrusion being located ata radial position relative to the center of the side plate such thateach protrusion extends into an associated mounting hole; and at leastone interlocking button protruding from an outer facing surface of atleast the first side plate and formed by a portion of the second sideplate being deformed into the first side plate so as to mechanicallyinterlock the two side plates and protrude from the outer facing surfaceof that side plate.
 2. A knot brush according to claim 1 wherein thebutton is formed in one of the protrusions and extends into the recessassociated with that protrusion.
 3. A knot brush according to claim 2wherein there are multiple buttons, each one formed in one of theprotrusions.
 4. A knot brush according to claim 2 wherein the knot platehas a thickness that is greater than the thickness of each side plate,wherein the perforations are slotted holes formed in the knot plate, theperforations being spaced substantially equally apart from one anotherand located at a common radial position from the center of the knotplate, and wherein each side plate includes half as many protrusions asthere are mounting holes in the knot plate.
 5. A knot brush according toclaim 2 wherein there are six mounting holes substantially equallyspaced circumferentially on the knot plate; and wherein there are threeprotrusions on each side plate substantially equally spacedcircumferentially on the side plate, the side plates being substantiallyidentical except that the protrusions on one side plate are offset fromthe protrusions on the other side plate by 60 degrees when the sideplates are mounted to the knot plate.
 6. A knot brush according to claim4 wherein each slotted hole has a length of about 0.200 inches and awidth of about 0.125 inches.
 7. A knot brush according to claim 6wherein the knot plate has a diameter of about 4.38 inches and athickness of about 0.110 inches, and wherein there are at least 76perforations formed in the knot plate, each perforation centered about1.984 inches from the center of the knot plate.
 8. A knot brushaccording to claim 5 wherein each side plate preferably has a diameterof about 4.72 inches and a thickness of about 0.05 inches, the centralportion being substantially planar is shape, wherein the knot plate hasa diameter of about 4.38 inches and a thickness of about 0.110 inches,and wherein there are at least 76 perforations formed in the knot plate,each perforation centered about 1.984 inches from the center of the knotplate.
 9. A knot brush according to claim 5 wherein the protrusions aresubstantially circular in shape with an outer diameter of about 0.571inches and protrude from the central portion of the side plate by about0.105 inches, and wherein the protrusions are spaced approximately 120degrees apart from one another.
 10. A knot brush according to claim 5wherein the centers of the mounting holes are located about 1.496 inchesfrom the center of the knot plate, and wherein each mounting hole has adiameter of about 0.610 inches and is located 60 degrees from anadjacent mounting hole.
 11. A knot brush comprising: a knot plate havinga plurality of perforations formed through the knot plate, theperforations being disposed circumferentially about the plate near aradially outer rim of the knot plate, and a plurality of mounting holesformed through the knot plate, the mounting holes being spaced apartfrom one another on the knot plate, each mounting hole located at aradial position inward from the perforations; a plurality of wirebundles are attached to the knot plate, each wire bundle including twoopposed end portions and a center portion extending through anassociated perforation in the knot plate, the end portions being atleast partially twisted together so as to secure the bundle to the knotplate; two side plates attached to the knot plate, the side plates beingsubstantially identical to one another and including an annular centralportion and curved support rim, the curved support rim adapted to assistin supporting the wire bundles, each side plate including at least threeprotrusions extending out from a surface of the annular portion, eachprotrusion forming a recess on the opposite surface of the side plate,the protrusions being spaced apart from one another on each side plate,each protrusion being located on the side plate such that eachprotrusion on a side plate extends into an associated mounting hole inthe knot plate but is not aligned with any protrusions on the other sideplate; and a plurality of interlocking buttons protruding out from asurface of a side plate, each button located in one of the recesses on aside plate, each interlocking button formed by a portion of the one sideplate being deformed into the other side plate so as to mechanicallyinterlock the two side plates and protrude from the outer facing surfaceof the other side plate.
 12. A method of forming a knot brush comprisingthe steps of: forming a plurality of perforations through a knot plate,the perforations being disposed circumferentially about the plate near aradially outer rim of the knot plate; forming a plurality of mountingholes in the knot plate, the mounting holes being spaced apart from oneanother on the knot plate, each mounting hole being located at a radialposition inward from the radial location of the perforations; providinga plurality of wire bundles, each wire bundle having two opposed endportions, inserting one end portion of each wire bundle through anassociated perforation in the knot plate; twisting the two end portionsat least partially along their length so as to secure the bundle to theknot plate; forming first and second side plates, each side plate havingan annular central portion and curved support rim, the curved supportrim adapted to assist in supporting the wire bundles; forming at leasttwo protrusions on each side plate, the protrusions extending out fromthe surface of the annular portion, the protrusions being spaced apartfrom one another; placing the first side plate on one side of the knotplate so that each protrusion on the side plate is aligned with onemounting hole on the knot plate; placing the second side plate on theopposite side of the knot plate so that each protrusion on the secondside plate is aligned with one mounting hole on the knot plate; andpunching a portion of one side plate into a protrusion on the other sideplate so as to force the punched materials on both side plates to deformand form an interlocking button on the opposite surface of the otherside plate, the interlocking button of material locking the side platesto each other and retaining the knot plate.
 13. A method of forming aknot brush according to claim 12 wherein the two side plates are formedso as to be substantially identical, and wherein prior to the step ofplacing the second side plate on the knot plate, the method involvesorienting the second side plate so that the protrusions on the secondside plate are not aligned with the protrusions on the first side plate.14. A method of forming a knot brush according to claim 13 wherein eachside plate includes three protrusions and the knot plate includes sixmounting holes; and wherein the step of orienting the second side plateresults in the protrusions on the second side plate being offset by 60degrees from the protrusions on the first side plate.
 15. A method offorming a knot brush comprising the steps of: forming a knot platehaving a plurality of perforations extending through the knot plate, theperforations being disposed circumferentially about the plate near aradially outer rim of the knot plate, the knot plate having a pluralityof mounting holes spaced apart from one another, each mounting holebeing at a radial position inward from the radial location of theperforations; attaching a plurality of wire bundles to the knot plate,each wire bundle being attached to an associated perforation byinserting one end portion of the wire bundle through the perforation inthe knot plate and twisting the end portion of the wire bundle to anopposite end portion of the wire bundle so as to secure the bundle tothe knot plate; forming first and second side plates, each side platehaving an annular central portion and curved support rim, the curvedsupport rim adapted to assist in supporting the wire bundles, each sideplate having at least two protrusions extending out from a surface ofthe annular portion, the protrusions being spaced apart from oneanother; placing the first side plate on one side of the knot plate sothat each protrusion on the side plate is aligned with one mounting holeon the knot plate; placing the second side plate on the opposite side ofthe knot plate so that each protrusion on the second side plate isaligned with one mounting hole on the knot plate while being offset fromthe protrusions on the first side plate; and punching a portion of thefirst side plate into a protrusion on the second side plate so as toforce the punched materials on both side plates to deform and form aninterlocking button on the opposite surface of the second side plate,the interlocking button of material locking the side plates to eachother and retaining the knot plate.